Development of process efficiency maps for selective laser sintering of polymeric composite powders: Modeling and experimental testing

Abstract This study develops process efficiency maps for selective laser sintering of polymeric composite powders to provide guidance for process parameter optimization via numerical modeling and experimental testing. Specifically, the sintering process for carbon nanotubes-reinforced PA12 nanocomposite powders is modeled to evaluate and predict the temperature distribution and dimensions of their melt pools. The numerical model takes into account the interaction between the laser beam and powder bed, the temperature-dependent material properties and the solid-liquid phase transition. The experimental testing is used to determine the material properties and validate the modeling predictions. The predicted melt pool features are utilized for the development of process efficiency maps that relate the printing productivity and laser energy consumption efficiency to the laser power and scanning speed.